Shape optimization of clinching tools using the response surface methodology with Moving Least-Square approximation

A response surface methodology (RSM), based on Moving Least-Square (MLS) approximation and adaptive moving region of interest, is presented for shape optimization problem. To avoid a local optimum and to obtain an accurate solution at low cost, an efficient strategy which allows to improve the RSM accuracy in the vicinity of the global optimum is presented. During the progression of the optimization procedure, the region of interest is moving and the search space is reduced by half around each local optimum. The clinch forming process is considered as an application example using the ABAQUS finite element code. The geometries of both the punch and the die are optimized to improve the joints resistance to tensile loading.